Thermwood Receives 32 Additive Manufacturing Patents as an Early Christmas Gift

Posted by Duane Marrett on Tue, Jan 04, 2022

Tags: Thermwood, Announcements, Local Motors, Thermwood LSAM, Patented, Boeing, Navair, Al Davis Torch, General Atomics

Thermwood routinely applies for patent protection on additive manufacturing technology it develops for its LSAM large format additive systems. During COVID, we received electronic copies of patents that were granted, however, the official hard copies were withheld.

A couple of days before Christmas 2021, we received a package containing the official hard copy of 32 additive manufacturing patents. This was certainly a one-day record for Thermwood and a welcome sight!

Thermwood Receives 32 Additive Manufacturing Patents

In addition to these latest patents, Thermwood already has a large portfolio of earlier issued patents covering the unique, large format (5x10 foot table and larger) 3D print technology it has developed. This LSAM technology is currently the most widely used large scale additive print technology operating in industry today. It’s used in a wide variety of industries including aerospace, transportation, heavy equipment, foundry and large decorative structures. It is being used to produce a diversity of products including aerospace patterns, molds and tooling, heavy equipment foundry patterns, bus chassis, large valve body foundry patterns and trim tooling. It was even used to print the tallest 3D printed structure in the world, the 92 foot tall Al Davis Memorial Torch at Allegiant stadium in Las Vegas.

Al Davis Memorial Torch Printed on Thermwood LSAM

Thermwood offers this unique patented technology on a wide variety of equipment, the largest, most diverse product offering of its kind available today. It includes a broad selection of machines, including single and dual gantry, fixed and moving table configurations, with both print-only and print-and-trim systems, from 5 by 10 foot to 20 by 60 foot print envelopes. We are working on even larger machines but that’s for another day.LSAM offers the broadest line of large scale additive systems available in the market today

Boeing Navair project

The primary focus of the patented LSAM technology is to reliably and repeatedly produce the highest quality, best fused, most homogeneous printed structures possible from a variety of reinforced thermoplastic polymer composites including those intended to operate at elevated temperatures. Although it is nice to have been granted these patents, it is even nicer to finally have the official hard copies in hand.

LSAM Info Request

Thermwood Adds Angle Layer Printing to its LSAM Large Scale Additive Systems

Posted by Duane Marrett on Tue, Nov 30, 2021

Tags: Thermwood, Announcements, Thermwood LSAM, VLP, ALP

Thermwood has added a third print orientation to its LSAM Large Scale Additive Manufacturing systems.

LSAM systems currently can print both horizontal and vertical layers if equipped with the Vertical Layer Print (VLP) option, available on most Thermwood LSAM machines. This new addition adds Angle Layer Printing (ALP) to the VLP option. Angle Layer Printing is the ability to print at a 45 degree angle.

LSAM Angle Layer Printing (ALP) shown

LSAM Angle Layer Printing (ALP) shown


LSAM Regular Vertical Layer Printing (VLP) shown

LSAM Regular Vertical Layer Printing (VLP) shown


LSAM Horizontal Layer Printing (HLP) Shown

LSAM Horizontal Layer Printing (HLP) shown


Maximum Print Flexibility

Each print orientation has advantages and limitations for a particular part design. Offering all three on the same machine, for the first time, means maximum print flexibility. All print orientations use the complete LSAM print head including exclusive LSAM print features such as the patented compression wheel and Thermal Sensor Layer Automation.

This helps maintain an even layer temperature throughout the print.  LSAM automatically adjusts the individual layer temperature to provide for superior layer fusion (as seen below).

Thermal Sensor Layer Automation

LSAM machines are currently operating in regular daily industrial production with many existing systems already equipped with Vertical Layer Print capability. The Vertical Layer Print (VLP) option has been replaced with a VLP/ALP option on new machines which offers both vertical and angle layer print capability, in addition to the standard horizontal layer print.

Angle Layer Print (ALP) can be easily and inexpensively added to machines operating in the field that already have the VLP option.

If a machine was purchased without VLP, the entire new VLP/ALP Print option, can be added to most machines already in operation. It can be done in the field, but is a bit more involved.

Angle Layer Printing Video

LSAM ALP Video

Broad Line of LSAM Systems Available

Thermwood’s LSAM large scale additive systems are the most widely used large scale composite thermoplastic additive equipment in industrial production today. Virtually all, if not all, large scale additive systems installed in the last several years have been Thermwood LSAMs. Processing a variety of reinforced composite polymers from room temperature ABS and PC to high temperature material such as PSU, PESU and PEI, they are used to produce molds and tools for the aerospace industry, patterns for the foundry industry and for a variety of other unique applications.

LineUp_LSAMrv421-2

LSAM systems are available in sizes from 5x10 foot to 15x60 foot in a variety of configurations including print only and full print and trim, making it the broadest product offering in the large scale additive arena. Print heads are available that can print thermoplastic composite material at rates from 200 pounds per hour to over 500 pounds per hour.

They have a variety of exclusive features including a temperature controlled compression wheel and automatic thermal layer speed control, both of which help assure the best possible fusion between printed layers.

With the addition of Angle Layer Print, these systems have become even more capable and more flexible.

Finished LSAM Angle Layer Print (rear view)

Finished LSAM Angle Layer Print (rear view)

finished_side_view_small

Finished LSAM Angle Layer Print (front view)

LSAM Info Request

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at CAMX 2021!

Posted by Duane Marrett on Fri, Oct 01, 2021

Tags: Thermwood, Announcements, Trade Shows, Large Scale, Thermwood LSAM, SABIC, LSAM Additive Printers, Airtech, High Temperature, Techmer PM, CAMX

Thermwood LSAM

Live Printing

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at CAMX 2021!

Thermwood will be printing high temp autoclave aerospace tooling on an LSAM Additive Printer 510 LIVE at CAMX 2021 in Dallas, TX, October 19th-21st in Booth #M44B.  LSAM Research Laboratory at Purdue ADDITIVE3D simulation software will be on display as well in adjacent Booth #M44, with Purdue representatives on site for demonstrations.  We will be printing a different material each day, donated by AIRTECH, SABIC AND TECHMER PM.  This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System! 

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at Rapid + TCT 2021

PXL_20210914_170431874

Free CAMX 2021 Exhibit Pass & 15% off Conference Registration Fee

Click the link below to Be Our Guest and register for a Free CAMX Exhibit pass and 15% off the Conference Registration Fee.

Free Exhibit Hall Pass Code: FREEEX021

15% off Full Conference Registration Code: FREEFULL21

CAMX 2021 Thermwood Free Exhibit Hall Pass Link

Make plans now to visit the Kay Bailey Hutchinson Convention Center and stop by Thermwood Booth #M44B to witness this live and in-person!


Thermwood LSAM Research Laboratory at Purdue University

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the recently announced Thermwood Research Laboratory at Purdue University (located in Purdue University's Composites Manufacturing Simulation Center - CSMC) will also be on hand to demonstrate their ADDITVE3D simulation software.

Additive3D Software from LSAM Research Laboratory at Purdue University


airtech_logo-1

AIRTECH High Temp Material - Tuesday, October 19th

On Tuesday, October 19th, we will be printing AIRTECH PEI DALTRAM I-350CF


SABIC

SABIC High Temp Material - Wednesday, October 20th

On Wednesday, October 20th we will be printing SABIC LNP™ THERMOCOMP™ AM EC004XXAR1 ULTEM compound.


Techmer PM

TECHMER PM High Temp Material - Thursday, October 21st

On Thursday, October 21st, we will be printing TECHMERPM PESU 1810 3DP.


 

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at Rapid + TCT 2021

Posted by Duane Marrett on Thu, Sep 02, 2021

Tags: Thermwood, Announcements, Trade Shows, Large Scale, Thermwood LSAM, SABIC, LSAM Additive Printers, RAPID + TCT, Airtech, High Temperature, Techmer PM

Thermwood LSAM

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at Rapid + TCT 2021

Live Printing

Thermwood will be printing high temp autoclave aerospace tooling on an LSAM Additive Printer 510 LIVE at RAPID + TCT 2021 in Chicago, IL September 13th-15th.  LSAM Research Laboratory at Purdue ADDITIVE3D Software will be on display as well, with Purdue representatives on site for demonstrations.  We will be printing a different material each day, donated by SABIC, TECHMER PM and AIRTECH.  This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System. 

Free Rapid + TCT Expo Pass & $100 off Conference Registration Fee

Click the link below to Be Our Guest and register for a Free Rapid + TCT Expo pass and $100 off the Conference Registration Fee.

Use Promo Code: 10016220

Free Rapid + TCT Expo Pass & $100 off Conference Registration Fee

Make plans now to visit the McCormick Center and stop by Thermwood booth #E7628 to witness this live and in-person!


Thermwood LSAM Research Laboratory at Purdue University

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the recently announced Thermwood Research Laboratory at Purdue University (located in Purdue University's Composites Manufacturing Simulation Center - CSMC) will also be on hand to demonstrate their ADDITVE3D simulation software.

Additive3D Software from LSAM Research Laboratory at Purdue University


SABIC

SABIC High Temp Material - September 13th

On Monday, September 13th we will be printing SABIC LNP™ THERMOCOMP™ AM EC004XXAR1 ULTEM compound.


Techmer PM

TECHMER PM High Temp Material - Tuesday, September 14th

On Tuesday, September 14th, we will be printing TECHMERPM PESU 1810 3DP.


airtech_logo-1

AIRTECH High Temp Material - Wednesday, September 15th

On Wednesday, September 15th, we will be printing AIRTECH PEI DALTRAM I-350CF


 

Large Scale Additive Manufacturing Book Published

Posted by Duane Marrett on Thu, Aug 19, 2021

Tags: Thermwood, Announcements, Large Scale, Thermwood LSAM, Boeing, Book, Additive Manufacturing Guide

THM_LOGO_600_DPI-2-1

A Manager's Guide to Large Scale Additive Manufacturing

A Manager's Guide to Large Scale Additive Manufacturing

This 315 page book, currently available as either an eBook or paperback hardcopy, is intended to help non-technical managers understand the basics behind a new technology that is revolutionizing production of large composite molds, tools and other industrial and commercial products.

Where to Purchase

This book is currently available from Amazon either as an electronic file or as a printed hardcopy.

PURCHASE ON AMAZON

 

 

Who This Book is For

If you are a manager in an industrial company who might benefit from large scale additive technology, or, if your company is actively exploring this technology, this book will give you the background you need to participate and make better decisions. It will also help you cut through the confusion and crosstalk that often accompanies a new technology like this.

More Info

Industrial additive manufacturing is currently being used successfully every day to produce some of the largest composite parts ever made. These include large aerospace molds and tools, foundry patterns for various industries, chassis for electric busses and what is likely the tallest 3D printed structure ever made. Although the process results in substantial savings and dramatically reduces lead time, much of industry today still doesn’t understand or trust it.

In this book, the author, who was instrumental in developing the technology actually being used in industry today, explains in everyday, no nonsense language what it is, how it works, what actually works, what doesn’t and why. He provides a guide for non-technical managers to help them understand the basics so they can evaluate how this new technology might impact their company.

He explores all aspects of this process in clear, easy to understand language including the print process, polymers, software, trimming, cost savings, time savings, computer simulation and the practical, real world, aspects of getting into large scale additive. He includes sometimes humorous vignettes about surprises, missteps and stumbles during initial technology development and how they were handled.

About the Author

Author Ken SusnjaraThe author, Ken Susnjara, is the founder, Chairman and CEO of Thermwood Corporation, the leading supplier of large scale additive systems for the production of thermoplastic composites. With almost 100 patents to his name, he was instrumental in the development of the underlying technology behind the most successful large scale additive systems today.

 

 

 

 

Boeing, Navy ManTech, NAVAIR AERMIP and Thermwood Collaborate on Large Scale Composite AM Cure Tool

Posted by Duane Marrett on Wed, Jun 30, 2021

Tags: Thermwood, Announcements, Large Scale, Thermwood LSAM, Navy, Composite Tooling, Boeing, Navair, Collaboration, Fleet Readiness Center

Thermwood was a key development partner in a Navy ManTech funded program issued to Boeing Research and Technology. The ManTech program was managed by Advanced Technology International (ATI) for the Office of Naval Research (ONR) with funding provided from the Naval Air Systems Command (NAVAIR) Aircraft Equipment Reliability & Maintainability Improvement Program (AERMIP). Fleet Readiness Center East (FRCE) was a key technical contributor for the low cost composite cure tooling technology development.

boeing_navair_release_8_18_21-2

Boeing, Navy ManTech, NAVAIR AERMIP and Thermwood Collaborate on Large Scale Composite AM Cure Tool

The Details

Thermwood’s Large Scale Additive Manufacturing (LSAM) machine was selected as the Large Format Additive Manufacturing (LFAM) machine to conduct the technology development. Several unique equipment features of the LSAM machine drove the selection. The high temperature autoclave cure tooling operating environment of 355 degree Fahrenheit and 85 psi provides a challenge for polymer based tool material. Additional composite cure tooling requirements for vacuum integrity and dimensional stability were validated during the development. Neil Graf Office of Naval Research, noted “Composite manufacturing is a strategic technology for future platforms and development of more cost effective tooling solutions would significantly benefit the implementation.”

The Process

FRCE provided a high contour mold line surface to Boeing for generating the composite cure tool. The mold line shape was very aggressive and would stretch the large format additive manufacturing technology processes capability. The spherically shaped portion of the mold line offered the largest challenge, as the unsupported 3D printed angle limitation of approximately 45 degrees provides an interesting obstacle to overcome for the spherical mold line section of the tool. Boeing rotated the 3D print plane 35 degrees to avoid encroachment of the build angle limitation.

Final 3D Print Model

Final 3D Print Model

The new innovative build plane approach eliminated the requirement for temporary support material for the aggressive mold line shape. The new build angle would test the LSAM machine limits in an area never explored previously. TechmerPM PESU CF 1810 high temperature print material was used for the composite cure tool. High temperature materials present additional challenges during print over low temperature materials such as ABS CF. Two interim support features were added to compensate for the center of gravity shift of the print. The LSAM machine performed flawlessly during the composite cure tool print. The tool was printed in 7 hours and 26 minutes using 610 lbs of material.

Composite Cure tool printing on Thermwood LSAM

Composite Cure Tool printing on Thermwood LSAM

The composite cure tool was machined in 53 hours using the LSAM gantry router machine. The tool datum features, and removal of interim members, were machined prior to removal from the bead-board. The Thermwood LSAM machine offers the ability to machine and 3D print on a single platform. The composite cure tool mold line part surface achieved at surface profile tolerance of .020” (+/-.010”).

Machining the Composite Cure Tool on Thermwood LSAM

Machining the Composite Cure Tool on Thermwood LSAM

The Boeing Research and Technology (BR&T) laboratory performed functional testing on the LFAM composite cure tool to ensure vacuum integrity and dimensional stability requirements were reached. The LFAM tool performed as expected and achieved all requirements. Several composite parts were fabricated from the tool. The tool durability was assessed during the multiple autoclave cure cycles and fabricated (3) composite parts. The tool maintained dimensional stability and vacuum integrity throughout the functional testing and composite part manufacturing.

LFAM tool after Autoclave Cure

LFAM tool after Autoclave Cure

The composite cure tool was printed and NC machined on Thermwood’s Large Scale Additive Manufacturing (LSAM) 1020 machine. The LFAM technology cost savings was estimated at 50% compared to traditional tool fabrication methods, and reduced tool fabrication lead-time by 65%. The cost savings and tool fabrication cycle time reduction could provide enormous benefit to any organizations performing low volume or custom composite part fabrication and repair.

Composite Part Fabricated from LFAM Tool

Composite part fabricated from LFAM tool

Nondestructive Inspection (NDI) was performed on the composite parts fabricated on LSAM tools. The NDI results did not indicate any porosity. Due to the complex shape of the composite demonstration part several NDI process were employed. X-ray and C-Scan results did not reveal any delaminations or defects.

The Bottom Line

The program benefited from a cooperative effort among several contributors to achieve success. The partnership between industrial technology leaders, Boeing and Thermwood coupled with the Office of Naval Research’s drive to transition technology, led to the successful program. “Collaborations such as this help expand the scope of capabilities of emerging large scale additive technology by addressing real world challenges that would be difficult for any single entity to define and address by itself. We look forward to new challenges moving forward”, says Thermwood CEO, Ken Susnjara.

Additional development is key to expand LFAM composite cure tooling implementation. Boeing Associate Technical Fellow Michael Matlack commented “The program provided significant results in validating additive manufacturing as a viable method of producing lower cost, capable tooling with substantial time savings over traditional methods.”

LSAM Info Request

Why LSAM?

Posted by Duane Marrett on Tue, May 11, 2021

Tags: Thermwood, Announcements, Thermwood LSAM, Why LSAM

Companies have been choosing Thermwood’s LSAM large scale additive manufacturing systems for their thermoplastic composite large part production.  In a newly released video, Scott Vaal, Thermwood’s LSAM Product Manager, addresses the question of "Why LSAM?"

why_lsam_version_1_0_rev_6

He addresses key aspects of the large scale additive manufacturing market and LSAM’s position in it. This video also addresses the current state of the art in additive print technology, offers a quick overview of the broad LSAM product line, slicing software, industry collaboration, additive system reliability, service, support, upgrade ability, plus other issues important to potential users and anyone interested in large scale additive manufacturing of thermoplastic composites.

Thermwood has found that many companies exploring large scale additive manufacturing don’t have a clear understanding of the current state of the market, the available technology or the capabilities of systems currently available. This video is intended to add a level of understanding, comfort and confidence that capable, proven and reliable large scale additive systems are not only available, but are already successfully operating in major industries every day, generating significant benefits and profits.

Largest Selection of Large Scale Additive Manufacturing Systems

Largest Selection of Large Scale Additive Manufacturing Systems

Largest Selection of Large Scale Additive Manufacturing Systems

With the introduction of the smaller LSAM Additive Printers plus these new wide table flagship LSAMs, Thermwood’s large scale additive manufacturing product line is, by far, the broadest available anywhere, with LSAM models from 5x5 foot to these new fifteen foot wide flagship models.

Learn More About Large Scale Additive Manufacturing Systems from the industry leader, LSAM by Thermwood.

LSAM Info Request

Thermwood Expands LSAM Product Line Yet Again

Posted by Duane Marrett on Tue, Apr 20, 2021

Tags: Thermwood, Announcements, Thermwood LSAM

Thermwood Corporation, manufacturer of the highly successful LSAM large scale thermoplastic composite additive systems, has announced the availability of even larger size machines than we currently offer.

The LSAM additive manufacturing system line is already the broadest in the industry with additive printers from a 5x5 foot table to large dual gantry print and trim systems up to 10x40 foot. Machines longer than 40 foot are available, but several 10x40 systems are the largest built to date.

LSAM 1520 Shown

LSAM 1520 Shown

With this new announcement, the large dual gantry print and trim machines are now available in a 15 foot width in addition to the current 10 foot width tables. As with the ten foot wide tables, the new fifteen foot wide table machines are available in lengths from twenty foot on, in ten foot increments.

New Heavier Gantry Design

The new machines utilize the new wide gantry design that was first developed for Thermwood’s LSAM 1010. The LSAM 1010 has both a print head and a trim head mounted on the same gantry, hence the need for a wide gantry even though the table is only 10x10 foot. The dual head combination on the 1010 weighs over 7,000 pounds, requiring a significant engineered gantry structure.

Larger Gantry Shown on an LSAM 1010

Larger Gantry shown on an LSAM 1010

The smallest table length available in the fifteen foot width LSAM is twenty foot, however, because of the modular design of the table and support walls, this length can be increased by ten foot increments. The most popular table lengths to date for the ten foot wide table LSAM machines have been twenty foot and forty foot.

40mm or 60mm Print Core Available

The new machines are equipped with the large LSAM print head structure which can be equipped with either the 40mm or 60mm print core. The 40mm core can print most polymers at about 200 pounds per hour while the 60mm core can print at over 500 pounds per hour. They can also be equipped with Thermwood’s patented Vertical Layer Print system, which makes it technically possible to print parts up to fifteen foot wide and as tall as the length of the table.

LSAM 1540 Shown

LSAM 1540 Shown

Same Powerful Features

The new machines are equipped with all the advanced features of the entire LSAM line including the thermal sensor layer automation system which automatically controls bead temperature at layer fusion producing virtually perfect bonding between layers.

As the market becomes more comfortable with the capability and reliability of LSAM technology, the new sizes open interesting opportunities in areas where really, really large parts are needed.

Three Print Head Options Available

Thermwood offers three print head options on various machines with maximum print rates of 100, 200 and over 500 pounds per hour. Although many believe that print rate determines how fast a layer can be printed, it is actually polymer cooling that determines how much time is needed between layers.

Print head output then determines how much bead can be printed in that time and thus how large a part that can be printed by that print head using that polymer. The Thermwood LSAM 60mm print head with 500 pound per hour maximum print rate can print the largest part layers possible today.

Largest Selection of Large Scale Additive Manufacturing Systems

Largest Selection of Large Scale Additive Manufacturing Systems

Largest Selection of Large Scale Additive Manufacturing Systems

With the introduction of the smaller LSAM Additive Printers plus these new wide table flagship LSAMs, Thermwood’s large scale additive manufacturing product line is, by far, the broadest available anywhere, with LSAM models from 5x5 foot to these new fifteen foot wide flagship models.

Learn More About Large Scale Additive Manufacturing Systems from the industry leader, LSAM by Thermwood.

LSAM Info Request

Purdue University to Establish Thermwood LSAM Research Laboratory

Posted by Duane Marrett on Tue, Apr 13, 2021

Tags: Thermwood, Announcements, Purdue, Thermwood LSAM, Thermwood LSAM Research Laboratory

Purdue University’s Composites Manufacturing Simulation Center (CMSC) and Thermwood Corporation have agreed to establish a large scale additive manufacturing laboratory to perform industry-funded research into large scale composite thermoplastic additive manufacturing.

Purdue Composites Manufacturing and Simulation Center

Thermwood LSAM Logo

The new facility will be located in Purdue’s Indiana Manufacturing Institute located in the Purdue Research Park in West Lafayette, Indiana and will be staffed and operated by Purdue CMSC personnel. The official name for the new facility is the Thermwood LSAM Research Laboratory at Purdue University”.

LSAM Additive Printer (10'x5')

Thermwood LSAM Additive Printer 10'x5'

About the Thermwood LSAM Reseach Laboratory at Purdue University

The new laboratory will be equipped with an LSAM 105 (ten-five) Large Scale Additive Printer and a corresponding 5 axis LSAM Additive Trimmer plus a variety of support systems. This installation is capable of printing and trimming complex geometries up to five feet by ten feet by four feet tall at print rates of up to 200 lbs. per hour. Commercial maximum print temperature for LSAM printers is usually limited to 450oC, however, this particular system has been modified to allow testing at even higher temperatures for experimentation with innovations in materials normally not used in additive manufacturing.

This effort will be enhanced with the newly announced ability of Thermwood’s LSAM large scale additive manufacturing systems to measure and precisely control the temperature of a printed layer at the instant a new layer is deposited. This will support research into the very core of the additive print process and will serve to provide validation of Purdue’s extensive additive manufacturing simulation capabilities for large scale additive manufacturing.


Not only will this effort improve the overall quality of large scale additive printing but it should also increase our knowledge and understanding of the basic process of fusing layers together into a homogeneous structure”
says Ken Susnjara, Founder, Chairman and CEO of Thermwood.


Extrusion deposition composites additive manufacturing is a major innovation that will contribute to the development of tailored products with unique performance and just in time availability.”  
Adds Dr. R. Byron Pipes, Executive Director of Purdue’s Composite Manufacturing & Simulation Center, the research organization where the LSAM system will be installed.


Purdue plans to partner with industry to provide services to enhance, encourage and expand the adoption of large-scale additive manufacturing for diverse industrial applications. They also plan to work with polymer suppliers to refine formulations and determine the ideal processing parameters necessary to produce the absolute highest quality large scale printed parts possible.

Collaborative efforts of this type bring together diverse organizations that each specialize in different aspects of this emerging technology and often produce results that none of the participants could possibly achieve on their own. Both Purdue and Thermwood are confident that this will be the outcome of their collaborative effort.

About the Composites Manufacturing and Simulation Center

The Composites Manufacturing and Simulation Center (CMSC) of the College of Engineering and the Purdue Polytechnic are located in over 30,000 square feet of the Indiana Manufacturing Institute building. CMSC consists of faculty experts in composites manufacturing, a professional staff of doctoral degree engineers, a support staff and research students in doctoral, masters and bachelor’s degree programs of the Schools Aeronautics and Astronautics, Chemical Engineering and Materials Engineering, as well as, the Department of Aviation Technology in the Polytechnic.

Purdue Manufacturing and Composites Research Center

A comprehensive set of laboratories is available at the IMI for the study of composites manufacturing processes, characterization of composite materials, and the validation of simulation software essential to development and verification of the digital twin concepts in composite manufacture and performance. Focus specialties include extrusion deposition additive manufacturing, composites autoclave processing of continuous fiber systems, compression and injection molding of discontinuous fiber composites, prepreg impregnation, infusion molding, sheet forming, complex mold-forming and hybrid continuous/discontinuous fiber systems. Workflow simulations are being developed to provide for end-to-end digital twins of these manufacturing processes. Accordingly, manufacturing informed performance predictions are a direct outcome of these workflow analyses.

3DEXPERIENCE Education Center of Excellence in Advanced Composites

To advance the development of digital twin, digital thread and model-based engineering, Dassault Systèmes and CMSC established the 3DEXPERIENCE Education Center of Excellence in Advanced Composites on October 28, 2020. The simulation center was founded on a seven-year partnership between Purdue University and Dassault Systèmes (2013-2020) and it is expected that this new engagement will bring significant benefits to the new relationship with Thermwood as the partners work together to bring the advantages of the digital age to society.

3DEXPERIENCE Platform and Thermwood LSAM

Together, they will advance the digital enterprise by developing the human talent essential to this new paradigm and by utilizing the Thermwood LSAM technology and the 3DEXPERIENCE platform to exercise digital twins of complex composites manufacturing and performance to demonstrate the power to predict phenomena that are understood today only by empirical experiences. The Partnership will work together to introduce these concepts to a wide range of industries within the advanced composites community from the original equipment manufacturer level to the supply chain industries. The philosophy of these relationships will be to create a learning environment at multiple levels – from advanced research in manufacturing and performance of advanced composites to the engagement of students at all levels needed to build the workforce of the future for Industry 4.0.

LSAM Info Request

Thermwood Announces Completion of the First LSAM 1010

Posted by Duane Marrett on Wed, Mar 31, 2021

Tags: Thermwood, Announcements, Thermwood LSAM, LSAM 1010

Thermwood has completed the first of a new type of additive print and trim system, the LSAM 1010. This is a fixed table, high wall system with both print and trim head mounted on a single gantry. Although with a ten foot by ten foot table, it is a bit smaller than the larger dual gantry flagship LSAM systems, it does require a significantly larger gantry.

LSAM 1010 Shown

The LSAM 1010 can both print and trim, but not at the same time. It uses the same 40mm print head that is standard on the larger LSAM systems and the same five axis trim head. It has the same 5 foot high print and trim capability of the larger machines. The addition of both of these on a single gantry adds two major new requirements.

Thermwood LSAM 1010 with print and trim head on same gantry

Two Major New Requirements

First, the gantry must be significantly longer to accommodate the width of both heads, while also allowing both heads to cover the entire table.

Thermwood LSAM 1010 with open doors

Also, the gantry must be significantly stronger to rigidly support both the print and trim head, which together weigh well over 7,000 pounds, resulting in a live load (the parts of the machine that actually move) of over 18,000 pounds. Despite the weight, the machine can move at speeds up to almost three feet per second.  This is not a small machine.

Thermwood LSAM 1010 with new larger gantry

New M400 Helps Build Large Machines

The production of this new gantry has been made possible by the commissioning of Thermwood’s new M400 five axis metal working system which can machine parts up to 35 feet long. The gantry design uses Thermwood’s slot and tab construction method which produces engineered steel structures that are extremely strong and stiff. 

Thermwood's M400 Helps Build Large Machines

More Details About the LSAM 1010

Since the LSAM 1010 has a fixed table, there is no practical part weight limitation. 

The LSAM 1010 has the same 200 lb maximum print rate capability of the larger flagship LSAM systems but is still priced well under the LSAM 1020, which is the smallest dual gantry LSAM available. 

The LSAM 1010 is also available as a “print only” machine for companies who already have the necessary machining capacity, bringing the price down even more. 

The LSAM 1010 is ideal for companies whose size requirements fit the available envelope and where a sequential process production rate (print and then trim) is adequate. It is also ideal for companies who need relatively large, heavy parts but don’t need trim capability. The lower price point also makes the LSAM 1010 easier to cost justify for a wider variety of end applications. 

Largest Selection of Large Scale Additive Manufacturing Systems

Largest Selection of Large Scale Additive Manufacturing Systems

The LSAM 1010 is part of the LSAM product line which offers the largest selection of large scale additive manufacturing systems available anywhere. There is a system available for about any large scale additive requirement from a 5x5 Additive (Print Only) Printer to giant, dual gantry, print and trim machines up to 40 foot long. Longer machines are available however, 40 foot are the longest machines produced to date. 

Large Scale Additive Manufacturing Systems from the industry leader, LSAM by Thermwood.

Learn More About Large Scale Additive Manufacturing Systems from the industry leader, LSAM by Thermwood.

LSAM Info Request